Method of making preformed mats

ABSTRACT

Preformed mats such as automobile floor mats are produced from a bat of loose fibers through which stitches are sewn along a plurality of courses, to hold the fibers together or to tack them to a backing such as a sheet of thermoplastic material, and so as to leave the bat readily expansible in all directions. The bat is then impregnated with a thermosetting resin and molded to shape at the polymerization temperature of the resin. The resulting mat tends to retain its molded shape.

United States Patent METHOD OF MAKING PREFORMED MATS 7 Claims, No Drawings US. Cl 156/93, 156/166 Int. Cl B32b 31/14 Field of Search 156/91, 92, 93, 166, 176

Primary Examiner-Carl D. Quarforth Assistant Examiner-S. R. Hellman Attorney-Young and Thompson ABSTRACT: Preformed mats such as automobile floor mats are produced from a bat of loose fibers through which stitches are sewn along a plurality of courses, to hold the fibers together or to tack them to a backing such as a sheet of thermoplastic material, and so as to leave the bat readily expansible in all directions. The bat is then impregnated with a thermosetting resin and molded to shape at the polymerization temperature of the resin. The resulting mat tends to retain its molded shape.

METHOD OF MAKING PREFORMED MATS The present invention relates to methods for producing preformed mats, more particularly for use as automobile floor mats.

it is well known that automobile floor mats are usually made of flexible material which takes the contour of the floor and which is readily removable for cleaning and the like. The flexibility improves the fit of the mat, but also presents the disadvantage that the matting may roll up or otherwise become misaligned.

The present invention provides a process for making such mats. which are stiffer than those which have heretofore been used and.which accordingly are preformed to the desired final shape. These mats may be easily installed and removed and have less tendency to roll up or become misaligned in use, at the same time that they remain easily removable for cleaning.

Accordingly, it is an object of this invention to provide a preformed matwhich does not readily roll up or become misaligned.

Another object of the present invention is the provision of a preformed mat that has good sound deadening properties.

Finally, it is an object of the present invention to provide a preformed mat which will be relatively simple and inexpensive to manufacture, easy to install and clean and replace, and rugged and durable in use.

Other objects and advantages of the present invention will become apparent from a consideration of the following disclosure.

i The process of the present invention comprises the following steps:

1. A flat bat of loose fibers is provided of the approximate extent of the finished pad. The fibers may be synthetic or natural or a mixture of the same, and may for example be polyethylene or wool or the like. It is to be noted, however, that the fibers are loose and are not woven in the form in which the bat is initially provided.

2. The bat of loose fibers is then sewn with a number of lines of stitching, either across the unsupported bat, or across the bat supported on a backing of fabric such as thermoplastic fiber or a sheet such as polyethylene sheeting or the like so that the bat is sewed to the backing. in other words, the bat as stitched can be backed or not; but the backing, if used, should be thermoplastic so that the bat remains expansible in all directions when heated.

3. The stitched bat, whether backed or not, is then impregnated with a suspension or solution of a thermosetting resin which may for example be an acrylic polymer suspension of the type sold by Kempem under the mark Fliesocol."

4. The impregnated bat is then dried and heated to the polymerization temperature of the thermosetting resin in a heated mold of a shape to impart to the bat the desired final planar or nonplanar shape of the mat, for a time sufficient to cure the resin. An example of the polymerization temperature and time for the above specific example is C. for 3 to 5 minutes.

5. The finished mat is then cooled and thereafter returns to the molded shape even when deflected.

The finished mat is light in weight and economical to produce, and is easily fitted to and removed from an automobile floor. It is quite durable and has high sound deadening capacity.

In view of the foregoing disclosure, it will be evident that all of the initially recited objects of the present invention have been achieved.

Although the present invention has been described in connection with preferred embodiments, it is to be understood that modifications and variations may be resorted to Without departing from the spirit of the invention, as those skilled in this art will readily understand. Such modifications and variations are considered to be within the purview and scope of the present invention as defined by the appended claims.

Having described my invention, I claim:

I. A process for making a preformed mat, comprising assemblin a flat bat of loose fibers, extending a plurality of lines of strtc mg through the bat or loose fibers, thereafter rmpregnating the bat with a thermosetting resin, heating the bat to at least the polymerization temperature of said resin for a time sufficient to cure the resin while molding the bat to a predetermined shape, and cooling the bat.

2. A method as claimed in claim 1, in which said bat is molded to a nonplanar configuration.

3. A method as claimed in claim I, in which said bat of loose fibers is secured to a backing of thermoplastic material by said stitching.

4. A method as claimed in claim 3, in which said backing is a thermoplastic fabric.

5. A method as claimed in claim 3, in which said backing is a sheet of thermoplastic material.

6. A method as claimed in claim 1, in which at least one side of said bat of loose fibers is exposed during said impregnating with a thermosetting resin.

7. A method as claimed in claim 1, in which one side of said bat of loose fibers is exposed and the other side of said bat of loose fibers is covered a backing of thermoplastic material during said impregnating with a thermosetting resin. 

2. A method as claimed in claim 1, in which said bat is molded to a nonplanar configuration.
 3. A method as claimed in claim 1, in which said bat of loose fibers is secured to a backing of thermoplastic material by said stitching.
 4. A method as claimed in claim 3, in which said backing is a thermoplastic fabric.
 5. A method as claimed in claim 3, in which said backing is a sheet of thermoplastic material.
 6. A method as claimed in claim 1, in which at least one side of said bat of loose fibers is exposed during said impregnating with a thermosetting resin.
 7. A method as claimed in claim 1, in which one side of said bat of loose fibers is exposed and the other side of said bat of loose fibers is covered a backing of thermoplastic material during said impregnating with a thermosetting resin. 